Homebuilt Scrutiny A guide to

homebuilt inspections RON ALEXANDER

s mentioned in previous articles, the FAA requires only one inspection of amateurbuilt experimental aircraft, which takes place after you've built it and just before the aircraft is ready for its first flight. During construction, the FAA strongly recommends that builders have knowledgeable people inspect the project, and EAA Technical Counselors usually make these in-process inspections. Before 1983 the FAA conducted a number of precover inspections, which took place during various stages of construction. Typically, an FAA inspector would scrutinize a homebuilt before the builder closed any surface. For example, if you were building a fabric-covered airplane, the FAA would have to inspect the airplane before you covered any surface with fabric. The FAA performed several similar inspections throughout the building phase, and it inspected the aircraft upon its completion and before issuing the airworthiness certificate. As interest in aircraft building began to grow in the 1980s, the FAA reassessed the need for precover inspections. Because of the success of EAA's Technical Counselor program, which dramatically improved the quality of homebuilt construction, in 1983 the FAA decided it would perform only one inspection prior to the initial flight test. To this day, this FAA inspection's purpose is to ensure that custom builders have constructed a safe and airworthy aircraft.

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Although the FAA only requires a final inspection, it's understood that someone other than the builder needs to inspect the project on a regular basis. Although the FAA requires that its personnel perform one inspection, it's understood that someone other than the builder needs to inspect the project on a regular basis. All builders make mistakes during construction, and without another set of eyes, these mistakes might go unnoticed and uncorrected. FAA Advisory Circular 20-27D, "Certification and Operation of Amateur-Built Aircraft," says, "In recent years, amateur builders have

adopted a practice whereby they call upon persons having expertise with aircraft construction techniques, such as the EAA Technical Counselors, to inspect particular components, e.g., wing assemblies, fuselages, etc., prior to covering, and to conduct other inspections as necessary. This practice is an effective means of e n s u r i n g construction integrity." In another paragraph AC 2027D says, "Amateur builders should have knowledgeable persons (i.e., FAA-certificated mechanics, EAA Technical Counselors, etc.) p e r f o r m precover inspections and other inspections as appropriate." It's clear that the FAA wants builders to have someone else look over their shoulder during the building of the aircraft. Because builders are concerned with their safety and that of their passengers, they seek these "eyes" and the advice and recommendations a second look often produces. These eyes belong to EAA Technical Counselors.

EAA Technical Counselor Program Technical Counselors are EAA members who have certain necessary qualifications with regard to aircraft building. These include having built or restored an airplane, or having an Airframe and Powerplant certificate; about half of all TCs have A&Ps. Technical Counselors are volunteers who Sport Aviation

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share their knowledge ignated Airworthiness Repand experience with resentative) will perform builders by inspecting your inspection instead of their projects. an FAA employee. In either These inspections are case, do not hesitate to not formal, paperworkcontact your final inspecintensive affairs. They are tor early in construction, if hands-on, friendly discusnot when you start work. sions about the best way Forming a relationship to build things. Most with this person is benefiTechnical Counselors special, and if you feel that cialize in certain conhe or she should inspect struction methods, such an item prior to the final as fabric covering, sheet inspection, then call and metal construction, com- From the paperwork to the Interior and instrument panel plac- ask the inspector to stop posites, etc., and all are ards, nothing goes unchecked during the final inspection. by. He or she has the final expected to have a good authority to ensure you grasp of basic aircraft are building a safe airmechanics. plane. EAA administers this program to ensure that What to Inspect builders present a wellconstructed, airworthy When it comes to inspecaircraft to the FAA for tions, first-time builders ask, final approval, and to "When do you begin the inpass on certain aviation spection process and what knowledge that will furitems should be inspected?" ther promote safety. The There is no specific Technical Counselor protimetable for in-process gram provides a means to inspections. They depend maintain the excellent repon the type of airplane utation that the amateur- When installing the engine, it's a good idea to have an EAA you're building, the conbuilt program has earned. Technical Counselor make several in-process inspections. struction methods, and TCs are not allowed to other variables such as sign Builder's Logs, and they don't can provide documented evidence of your building experience. need to. As the builder, you record in-process inspections. The records For example, if you're building a the TC's visit in your log and sign should indicate what was in- tube-and-fabric airplane from plans, the entry. When it comes time for spected, by whom, and the date of a Technical Counselor should inthe FAA inspection, you endorse the inspection." [Emphasis added.] spect your welds after you finish the EAA Technical Counselors do not fuselage. If you're new to welding, your project's airworthiness. Documenting the Tech Coun- charge for their services. If a TC must you might want the TC to look at selor's visits is i m p o r t a n t . FAA travel some distance to inspect your your work after you tack-weld the Order 8130.2D, "Airworthiness project, what financial arrangements fuselage or after you complete your Certification of Aircraft and Re- you make for travel, lodging, and first few finish welds. If you're buildlated Products," guides the FAA meals is between you and the TC. ing a sheet-metal airplane, having inspector through his or her in- Most Technical Counselors are mem- a TC inspect the wing spars before spection of your project. In Section bers of EAA Chapters, and the easiest you attach the ribs would be a 7, number 128(a) is says: "The FAA way to find the TC in your area is to good place to start. In most cases common sense will airworthiness certification process join the Chapter. You can also find will consist of a general airworthi- Tech Counselors by location or con- almost certainly tell you when to ness inspection of the aircraft. This struction specialty by clicking the begin this process. It's never a bad will be accomplished after the air- members only button on the main idea to meet with your Technical craft is completed and prior to the page of www.eaa.org. Then select the Counselor before you start conissuance of an airworthiness cer- "aviation advisors" button on the struction so the two of you can tificate. During this inspection, the main page of the members-only sec- discuss the project and map out a general inspection schedule in adFAA should not request extensive dis- tion, or by calling 920/426-6864. In some areas an FAA DAR (Des- vance. This also is a good way to get assembly of the aircraft if the builder MAY 2000

valuable building tips that may save you time and frustration later. Meeting with others who are building the same airplane before and during your construction offers the same benefits. You can never have too many sets of eyes looking at your work. The more critical the better. Put your ego aside and let others critique your workmanship.

make sure you're not sealing any tools inside a wing or control surface. Like a surgeon who inadvertently leaves something behind, you'll have to open what you've just closed to remove the tool because leaving it there will do damage over time. After enclosing the component a TC should inspect it again. This examination focuses on the outer skin and makes sure Component Parts it's properly attached to the un| derlying structure. On a Overall, in-process inspecsheet-metal airplane the TC is looking for such things as proptions concentrate on basic construction techniques and erly spaced and attached rivets. finding problem areas before On a fabric airplane the TC is the area is sealed from later looking for things like proper rib view. The final inspection, aclacing, seam location, and use of complished by the FAA, will finishing tapes. . ; ••'•. • Assessing the quality of comview more general areas because most of the internal compoposite construction is more difficult. Layups of reinforcenents are not fully accessible ment cloth that are incorrectly during the final inspection. applied are often hard to detect. Technical Counselors should If you have built the part under inspect several critical areas bethe right temperature and hufore you cover the control midity conditions, you can be surfaces, wings, and fuselage. somewhat sure that the cloth is Inspect the wing spars for any properly attached. The inspecobvious defects, even if the kit tor will want to look for obvious manufacturer provided a fin- At the top of the critical inspection list are ished spar. Whether the spar is any items that are bolted together. Their se- flaws such as delamination in a skin area. metal, wood, or composite, curity determines your safety. Regardless of the constructhoroughly examine it for damage or defects. If metal, these eral Technical Counselor visits, tion method, at this stage the parts things may be obvious, but such and they are good times to ask any may or may not be painted. Cosmay not be the case with other questions you may have. At the metics are not as important with materials. Have a Tech Counselor same time, if you have questions, this inspection as the actual qualwith wood or composite experi- don't wait to ask them. Call the kit ity of the construction. manufacturer's builder-assistance ence inspect it with a critical eye. Assembly Inspect the wing again after at- department and/or your TC. Gettaching all the ribs and running the ting answers to questions as they After you've covered all parts control cables or tubes. In compos- arise keeps construction moving forward and reduces the chance of with fiberglass, metal, wood, or ite aircraft construction, proper fabric, it is time to assemble them bonding of certain component making mistakes. into an aircraft. Schedule periodic parts is critical. As you build, make Closing Parts inspection as you assemble the sample layups using the same resins parts because how they are conthat are used for the bonding so the As soon as the Technical Coun- nected is important. The Technical TC can inspect the samples. Follow the same sequence for selor inspects a component's Counselor will be looking for such the aircraft's other major compo- innards, you can cover or enclose it. things as use of the proper hardnents such as the fuselage, tail Before you do this, however, make ware, bolt size, and placement and feathers, etc. This will entail sev- your own surgical inspection to safetying of nuts, etc. Sport Aviation

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The TC will also want to inspect selor performs his or her final inBuilding Stage ll the control linkages, control surface spection before the FAA inspector hinges, landing gear attachment visits your project for certification. • Start your B u i l d e r ' s Log (see points, and proper wheel alignment. At this point you want as many March Sport Aviation). Certainly wing attach and strut at- qualified sets of eyes as you can • If you desire a specific N-numtach points should be observed for find to look the aircraft over, and ber, apply for it now. proper bolts and attachment. we'll discuss this phase in detail in • Be sure to get a bill of sale from In general, the Tech Counselor an upcoming article. the kit manufacturer. should inspect all of the parts as When you and the TC made your • Ensure the following items are they are assembled before you at- final pre-FAA inspection it's a good completed: tach any fairing that would hide idea to create and use a checklist to Instruments, controls, etc., are component attachments. Schedule make sure you and your project are properly marked these in-process inspections on a ready for the FAA and that all the Emergency Locator Transmitter regular basis. It's time for a TC visit FAA forms, documents, etc., are (ELT) installed • - ' • when the tail is in place. When the complete. You should create and Passenger warning placard ingear is in place—time for a visit. start using this checklist when you stalled Electrical wiring is another area of start construction, not a week before Experimental lettering affixed concern. Looking for the proper the FAA inspector's visit, because it N-number on the airframe will ensure that you're ready for routing of wiring, connections, etc., Identification plate on the airis very important. your certification inspection. frame Engine installation is time for another important Before Final Inspection inspection. Besides the enEAA SportAir Workshops • Complete the Affidavit gine mount's attachment June 2-4 Griffin, Georgia (GlaStar Assembly) of Ownership (AC Form the TC will scrutinize the June 24-25 Frederick, Maryland 8050-88). firewall to ensure that it's July 7-9 Griffin, Georgia (RV Assembly) • Fill out the Application made of the proper material August 26-27 Shawnee, Oklahoma for Airworthiness Certifiand that grommets protect cate (FAA Form 8130-6). things passing though it For more information or to register, call • Apply for registration from chafing. The inspec- 800/967-5746 or visit the EAA SportAir Work(do this at least 90 days tion will ensure that fluid shop website at www.sportair.com. prior to inspection), AC lines and filters aren't lo- «. Form 8050-1. cated near the exhaust .fi-; • Fill out the Eligibility system and that the throttle, mixture, The following generic checklist Statement-Amateur Built Airand prop controls are properly should aid you in completing the craft. routed. Spark plugs should be se- necessary items. Modify it to meet • Determine where you want to curely in place and the engine the particular needs of your project. test fly the airplane. properly grounded. These are just a • Compose a letter to accompany Prior to Building few examples of items you and the the application for airworthiTC must check and recheck to ensure ness (a sample may be found in • Obtain all forms, advisory circusafety. Engine compartments can be AC 20-27D). lars, etc., from your local FAA very cluttered, requiring close exami• Send this letter to the FAA innation to detect potential problems. office. spector or DAR who will perform • Contact the FAA Inspector or Schedule another TC visit when the final inspection. DAR who will be inspecting you install the interior, upholstery, • Complete the weight and balyour airplane, introduce yourinstruments, avionics, and other ance i n f o r m a t i o n for your self, and tell the inspector what major components that comprise you're doing. ••>'••"••'• '•••'•••< -••;£..-.'/•.>•! i airplane. even the simplest airplane. When • Purchase a logbook for the air• Review the plans and/or assemthe airplane is complete, have the frame, engine, and propeller. TC inspect it one more time, playbly manual of your airplane. Following this simple checklist ing the role of the FAA inspector. • Contact the EAA Technical Counselor/s who will be work- will assist you in properly preparThis prepares you for the last step ing for the final FAA inspection. of the construction process. ing with you. • Review FAA Advisory Circular Next month we will take a detailed look at the required items listed Final Inspection Checklist 20-27D. • Purchase reference material such above, such as placards, N-numbers, ELT, etc. as Advisory Circular 43-13. Naturally, your Technical Coun46

MAY 2000